Ferrule-based optical component assemblies

ABSTRACT

In one embodiment, an optical transceiver assembly includes an active component substrate, first and second fiber securing devices, and a holder device coupled to the active component substrate. The holder device includes an active optical component recess that encloses a first and second active optical component of the active component assembly, and first and second fiber-locating holes having an engagement feature at the active optical component recess such that an end of first and second fibers inserted into the first and second fiber-locating holes are aligned with the first and second active optical components along the x-, y-, and z-axes. In another embodiment, an optical component assembly includes an active component substrate having a solder ring, a fiber securing device, and an active optical component on the active component substrate. The fiber securing device is aligned with the active optical component by the solder ring.

BACKGROUND

1. Field

The present disclosure generally relates to optical component assembliesfor optically coupling an optical fiber to an active optical component,such as a laser diode or a photodiode.

2. Technical Background

Fiber optic cables are an attractive alternative to bulky traditionalconductor cables (e.g., copper), especially as data rates increase. Asthe use of fiber optics migrates into numerous consumer electronicsapplications, such as connecting computer peripherals by the use offiber optic cable assemblies, there will be a consumer-drivenexpectation for cables having improved performance, compatibility withfuture communication protocols, and a broad range of use. For example,it is likely that consumer demand will be for a fiber optic cable thatis compatible with universal serial bus specification version 3.0 (USB3.0). Devices that communicate using electronic communication protocols(e.g., USB 3.0) require an electro-mechanical interface, such as a USBplug. However, conventional fiber-coupled transceivers have industrystandardized connections to define an opto-mechanical interface for theinstallation and removal of fiber optic cables using standardized plugsand jacks.

Accordingly, alternative optical component assemblies, such as opticaltransceiver assemblies, and active optical cable assemblies that enableelectro-mechanical interfaces with electronics devices are desired.

SUMMARY

Embodiments of the present disclosure relate to optical componentassemblies and, more specifically, to optical component assemblieshaving a fiber securing assembly is configured to align an end of afiber optic cable with an active optical component, (e.g, a laser diodeor a photodiode). Features of the fiber securing component may allow thefiber securing assembly to be passively aligned with, and coupled to,the substrate such that the ends of optical fibers maintained by thefiber securing component are secured and substantially located at aspecific, spatial optical coupling location with respect to the activeoptical component. Embodiments also relate to optical transceiverassemblies for optically coupling optical fibers to a light emittingcomponent and a light receiving component, and active optical cableassemblies having an optical fiber(s) optically coupled to an activeoptical component.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate embodiments, andtogether with the description serve to explain principles and operationof the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The components of the following figures are illustrated to emphasize thegeneral principles of the present disclosure and are not necessarilydrawn to scale. The embodiments set forth in the drawings areillustrative and exemplary in nature and not intended to limit thesubject matter defined by the claims. The following detailed descriptionof the illustrative embodiments can be understood when read inconjunction with the following drawings, where like structure isindicated with like reference numerals and in which:

FIG. 1A schematically depicts a partially exploded, top perspective viewof an active optical cable assembly according to one or more embodimentsshown and described herein;

FIG. 1B schematically depicts a cross-sectional view of the fiberoptical cable of the active optical cable assembly depicted in FIG. 1Aaccording to one or more embodiments described and illustrated herein;

FIG. 1C schematically depicts a top perspective view of an opticcomponent assembly having first and second fiber insertion devicescoupled to first and second solder rings according to one or moreembodiments shown and described herein;

FIG. 1D schematically depicts a partial cross-sectional, top perspectiveview of the optical component assembly depicted in FIG. 1C according toone or more embodiments shown and described herein;

FIG. 1E schematically depicts a partial cross-sectional, side view ofthe optical component assembly depicted in FIG. 1C according to one ormore embodiments shown and described herein;

FIG. 1F schematically depicts a top view of the optical componentassembly depicted in FIG. 1C according to one or more embodiments shownand described herein;

FIG. 1G schematically depicts a side view of the optical componentassembly depicted in FIG. 1C according to one or more embodiments shownand described herein;

FIG. 2A schematically depicts a top perspective view of an opticalcomponent assembly having a single fiber securing device according toone or more embodiments shown and described herein;

FIG. 2B schematically depicts a partially exploded, top perspective viewof the optical component assembly depicted in FIG. 2A according to oneor more embodiments shown and described herein;

FIG. 2C schematically depicts a transparent, top perspective view of theoptical component assembly depicted in FIG. 2A according to one or moreembodiments shown and described herein;

FIG. 2D schematically depicts a top view of the optical componentassembly depicted in FIG. 2A according to one or more embodiments shownand described herein;

FIG. 2E schematically depicts a cross-sectional view of the opticalcomponent assembly depicted in FIG. 2A according to one or moreembodiments shown and described herein;

FIG. 3A schematically depicts a front, top perspective view of anoptical component assembly having a fiber securing device and a collaraccording to one or more embodiments shown and described herein;

FIG. 3B schematically depicts a partially exploded, top perspective viewof the optical component assembly depicted in FIG. 3A according to oneor more embodiments shown and described herein;

FIG. 3C schematically depicts a partially exploded, top perspective viewof the optical component assembly depicted in FIG. 3A according to oneor more embodiments shown and described herein;

FIG. 3D schematically depicts a partially transparent view of theoptical component assembly depicted in FIG. 3A according to one or moreembodiments shown and described herein;

FIG. 3E schematically depicts a rear, top perspective view of theoptical component assembly depicted in FIG. 3A according to one or moreembodiments shown and described herein;

FIG. 3F schematically depicts a bottom view of the optical componentassembly depicted in FIG. 3A according to one or more embodiments shownand described herein;

FIG. 3G schematically depicts a rear, bottom perspective view of theoptical component assembly depicted in FIG. 3A according to one or moreembodiments shown and described herein;

FIG. 4A schematically depicts a front, top perspective view of anoptical component assembly having a holder device and two fiber securingdevices according to one or more embodiments shown and described herein;

FIG. 4B schematically depicts a partially exploded, top perspective viewof the optical component assembly depicted in FIG. 4A according to oneor more embodiments shown and described herein;

FIG. 4C schematically depicts a transparent, top perspective view of afiber securing assembly of the optical component assembly depicted inFIG. 4A according to one or more embodiments shown and described herein;

FIG. 4D schematically depicts a cross-sectional view of the opticalcomponent assembly depicted in FIG. 4A according to one or moreembodiments shown and described herein; and

FIG. 4E schematically depicts a front, bottom perspective view of theoptical component assembly depicted in FIG. 3A according to one or moreembodiments shown and described herein.

DETAILED DESCRIPTION

Some aspects of the present disclosure are directed to optical componentassemblies, optical transceiver assemblies and active optical cableassemblies. According to various embodiments, the optical componentassemblies, the optical transceiver assemblies and the active opticalcable assemblies described herein may utilize cost effective means toaccurately position optical fibers relative to active components (e.g.,photodiodes or laser diodes of a transceiver circuit) by passivealignment means. Embodiments described herein utilize a fiber securingassembly having an alignment component to precisely guide and positionan end of an optical fiber relative to the active component in x-, y-,and z-axis directions.

Embodiments may be utilized in, or otherwise related to, active opticalcable assemblies that communicatively couple a host device to a clientdevice, such as an electro-optical cable, wherein electrical signalsgenerated by a host or client device are converted to optical signals bya transceiver circuit and transmitted over one or more optical fibers.Optical signals received by a host or client end of the active opticalcable assembly are converted from optical signals into electricalsignals by the transceiver circuit, wherein the electrical signals arethen provided to the host or client device. Although embodiments may beillustrated and described within the context of the USB 3.0 standard,embodiments are not limited thereto. It is contemplated that embodimentsmay be implemented in future standards of USB, as well as othercommunication protocols. Optical component assemblies, opticaltransceiver assemblies, and active optical cable assemblies will bedescribed in further detail herein with specific reference to theappended figures.

Generally speaking, due to the high data rates of USB 3.0 (e.g., 4.8Gb/s), the cable length of reasonably-sized, traditional passiveelectrical conductor cable assemblies are limited to about 3 meters orless due to skin and dielectric losses intrinsic to electricalconductors and dielectric materials. Further, conductor cables that arecompatible with USB 3.0 at the specified distance of 3 meters are verybulky and put significant stress on the small connectors that are usedon laptops and consumer devices, such as cameras or camcorders. Becauseof these limitations, there may be interest in a fiber optic cable foruse with USB 3.0. A fiber optic cable may be dramatically thinner, moreflexible, easier to carry for portable use, and may put much less stresson the connectors used in small, handheld devices. Additionally, a fiberoptic cable assembly may comprise cable lengths of 100+ meter spans,allowing USB 3.0 protocols (as well as other protocols) to be used inmarkets such as video delivery and thin-client computing.

One embodiment of an active optical cable assembly 100 is illustrated inFIG. 1A. The active optical cable assembly 100 generally comprises aconnector 110 and a fiber optic cable 150. A second connector (notshown) is at an opposite end of the fiber optic cable 150 from theconnector 110 and includes the same components and configurations as theillustrated connector 110. The connector 110 may further comprise a topconnector housing 112, a body 119, a shield 117, and a male connectorend 115. It should be understood that the connector 110 may take on avariety of configurations, and that embodiments are not limited to thephysical configurations of the connector 110 illustrated in FIG. 1A. Forexample, the male connector end may be configured as a female connectorend in some embodiments, or may possess a different configuration whenthe active optical cable is implemented in a system that uses acommunication protocol other than USB (e.g., Firewire, Thunderbolt,etc.). Accordingly, it should also be understood that no limitations areintended by the depiction of male and female connector configurationsdepicted in the figures.

An active circuit 111 may be positioned within the body 119 and coveredby the shield 117 and the top connector housing 112. As illustrated inFIG. 1A, optical fibers 156 a and 156 b are mechanically coupled to theactive circuit 111. The active circuit 111 may be operable to convertelectrical and optical signals to provide communication between a hostdevice and a client device over the active optical cable assembly 100using the USB 3.0 standard in one embodiment. In the illustratedembodiment, the active circuit 111 generally comprises an opticalcomponent assembly 120, a mother printed circuit board 113, and anactive integrated circuit 114. The active circuit 111 is configured toconvert between the electrical and optical signals. The opticalcomponent assembly 120, and the active integrated circuit 114, may bemounted on the mother printed circuit board 113 and positioned withinthe body 119 of the connector 110.

FIG. 1A illustrates the active circuit 111 as comprising an opticalcomponent assembly 120 that is separate from the active integratedcircuit 114. However, it is contemplated that the components of both theoptical component assembly 120 and the active integrated circuit 114 maybe provided in a single assembly (e.g., the active integrated circuit114 may also be included as a component on the optical componentassembly 120).

As described in more detail below, the optical component assembly 120generally comprises an active component assembly 121, one or more activecomponents (not shown in FIG. 1A), and a fiber securing assembly 122a/122 b. The fiber securing assembly 122 a/122 b is utilized toprecisely locate the ends of the optical fibers 156 a, 156 b to theactive optical components of the optical component assembly 120 in thex-, y-, and z-axis directions by passive alignment. In one embodiment,the ends of the optical fibers 156 a, 156 b are within ±40 μm in x-, y-,and z-axis directions. As described and illustrated herein, the fibersecuring assembly may take on a variety of configurations.

Any suitable fiber optic cable may be utilized for the optical fiberattach. Referring now to FIG. 1B, one non-limiting example of the fiberoptic cable 150 is illustrated schematically in cross section. It shouldbe understood that other fiber optic cable configurations may beutilized, including those with more or fewer optical fibers, as well asthose with more or fewer conductors. The exemplary fiber optic cable 150includes a polymer jacket 153 having an outer periphery and an innerperiphery with the inner periphery defining a channel 155. The channel155 is the same as an optical fiber envelope. The polymer jacket 153 maysurround the channel 155 and the channel 155 may extend the entirelength of the fiber optic cable 150. The fiber optic cable 150 furthercomprises a plurality of conductors 154 a, 154 b (e.g., electricallyconductive wires) that may supply power to peripheral devices. The twoconductors 154 a, 154 b are capable of electrically coupling the hostactive circuit to the client active circuit. For example, the twoconductors 154 a, 154 b may receive and provide a voltage and a groundreference potential. The two conductors 154 a, 154 b may be made of aconductive material, such as copper. It should be understood thatadditional conductors may be utilized to transmit additional electricalsignals through the fiber optic cable 150. In one embodiment, noconductors may be present within the fiber optic cable. The conductors154 a, 154 b may be surrounded by an insulating material 158 a, 158 b,respectively. It is not a requirement that the conductors 154 a, 154 bsurrounded by an insulating material 158 a, 158 b.

Data-carrying buffered optical fibers 156 a, 156 b are also includedwithin the fiber optic cable 150. Optical fiber 156 a may be configuredto propagate optical signals in a first direction, and optical fiber 156b may be configured to propagate optical signals in a second direction.In another embodiment, the optical fiber 156 a may comprise a pluralityof optical fibers, and optical fiber 156 b may also comprise a pluralityof optical fibers configured to propagate optical signals in a firstdirection and second direction, respectively. In yet another embodiment,a single optical fiber (or a plurality of optical fibers) may beincluded in the fiber optic cable 150. The single optical fiber may beconfigured to propagate optical signals bi-directionally (e.g., byoperation of a switch, a multiplexer and/or a beam splitter).

The optical fibers 156 a, 156 b depicted in FIG. 1B are also eachsurrounded by a jacket 159 a, 159 b. The conductors 154 a, 154 b and theoptical fibers 156 a, 156 b are positioned within the channel 155. Insome embodiments, the conductors 154 a, 154 b may be arranged within thepolymer jacket 153. The optical fibers 156 a, 156 b are free totranslate within the channel 155 when the fiber optic cable 150 is bent.

The shape of the channel 155, or optical fiber envelope 155, isestablished so that no matter how the fiber optic cable 150 is bent, theoptical fibers 156 a, 156 b will never be bent below their minimum bendradius. The channel 155 as illustrated is “cross” shaped. However, thereis no requirement that the channel 155 be cross shaped and may be anyshape necessary to accommodate optical fiber translation so when thefiber optic cable 150 is bent, optical fibers 156 a, 156 b are not bentto a radius below the minimum bend radius. The channel 155 shape andorientation may also depend on the preferred of bending and locations ofother elements within the fiber optic cable 150.

In some embodiments, the fiber optic cable 150 further includes astrength material, such as an aramid yarn or Kevlar. The strengthmaterial may be arranged within the channel 155. It is not required thatthe strength material be arranged as such, or even required, and may bearranged within the jacket 153 or the channel 155 in any convenientorientation or arrangement. The strength material may surround theoptical fibers 156 a, 156 b and conductors 154 a, 154 b. The strengthmaterial may be positioned in a space between the conductors 154 a, 154b, the optical fibers 156 a, 156 b and the jacket 153. The strengthmaterial allows the optical fibers 156 a, 156 b to move to a limitedextent within the jacket 153. It should be understood that otherarrangements of the components illustrated in FIG. 1B are within thescope of this disclosure.

In one embodiment, the fiber optic cable 150 is capable of being bentwhile successfully propagating optical signals. For example, the opticalfibers may have a minimum bend radius of approximately 1.2 mm orgreater. The minimum bend radius is the smallest radius the opticalfibers 156 a, 156 b within the fiber optic cable 150 may be bent beforeexcessive attenuation of the optical signals of the optical fibers 156a, 156 b occurs. In one embodiment, the predetermined acceptableattenuation range is about 1.5 dB to 2.0 dB, and the minimum bend radiusis about 1.2 mm or greater. It should be understood that fiber opticcables having other properties may be used.

Referring now to FIG. 1C-1G, an optical component assembly 120 accordingto the embodiment illustrated in FIG. 1A is depicted in greater detail.Referring specifically to FIG. 1C, the optical component assembly 120generally comprises an active component assembly 121 and a fibersecuring assembly 122 a/122 b. FIGS. 1D-1F depict the fiber securingassembly 122 a/122 b in cross section to depict interior components ofthe active component assembly 121. The active component assembly 121comprises an active component substrate 127, one or more integratedcircuits 128 (or other electronic components), and two active opticalcomponents in the form of a light emitting component 141 (e.g., a laserdiode, such as a VECSEL laser diode) and a light receiving component 142(e.g., a photo detector operable to detect optical signals emitted by acorresponding light emitting component). The light emitting component141 and the light receiving component 142 are coupled to a surface 123within a first solder ring 126 a and a second solder ring 126 b,respectively, of the active component substrate 127. In alternativeembodiments, the active component assembly 121 may have more or feweractive optical components (e.g., only a light emitting component, only alight transmitting component, several pairs of light emitting and lighttransmitting devices, etc.). For the embodiments described herein,active component substrate assemblies that have both a light emittingcomponent and a light receiving component may be referred to as atransceiver substrate assembly having a transceiver substrate, and theoverall assembly may be referred to as an optical transceiver assembly.Embodiments may have only one active optical component, as well aplurality of active optical components depending on the application ofthe optical component/transceiver assembly.

The active component substrate 127 may be made of a dielectric material,such as a printed circuit board material (e.g., FR-4), and may beelectrically coupled to the mother printed circuit board 113 byelectrically conductive castellations 125. The electrically conductivecastellations 125 may take on a variety of configurations to enable theactive component assembly 121 to be electrically coupled to the motherprinted circuit board 113 (e.g., by pressure sensitive anisotropicconductive film or conventional solder reflow methods). In oneembodiment, through-holes 129 a and 129 b may be provided through athickness of the active component substrate 127, such as for mountingpurposes.

Referring to FIG. 1D, the active component substrate 127 may include afirst solder ring bond pad 135 a and a second solder ring bond pad 135b. The light emitting component 141 may be coupled to a light emittingcomponent bond pad (not shown) within the first solder ring bond pad 135a, and the light receiving component 142 may be coupled to a lightreceiving component bond pad (not shown) within the second solder ringbond pad 135 b. The light emitting component pond pad is preciselyaligned with the first solder ring bond pad 135 a in the x- and y-axisdirections, and the light receiving component bond pad is preciselyaligned with the second solder ring pond pad 135 b by the use of asingle mask when fabricating the active component substrate 127. Thefirst and second solder rings 126 a and 126 b are created by applicationof a solder material with a known surface tension to the first andsecond solder ring bond pads 135 a, 135 b (or another material with aknown surface tension, such as an epoxy material). The surface tensionof the solder material (e.g., C4 solder) may provide for a solder ringhaving a known height in the z-axis direction. As described below, thefirst and second solder rings 126 a and 126 b may provide an alignmentcomponent that allows for precise positioning of the fiber securingdevices 122 a/122 b in the x-, y- and z-axis directions. It is notedthat, due to the known surface tension of the solder, the solder ringsare self-assembling structures that allow for the precise alignment ofan end of an optical fiber to the active optical component.

In the embodiment illustrated in FIGS. 1A-1G, the optical componentassembly 120 comprises a first fiber securing device 122 a and a secondfiber securing device 122 b. More or fewer fiber securing devices may beutilized depending on the number of active components utilized in theoptical component assembly. The first and second fiber securing devices122 a, 122 b are configured to receive and secure an optical fiber, suchas optical fibers 156 a and 156 b (FIG. 1E). The first and second fibersecuring devices 122 a, 122 b may be configured as a ferrule having afirst fiber installation feature 130 a and a second fiber installationfeature 130 b, respectively, fully extending therethrough. The first andsecond fiber installation features 130 a, 130 b comprise a fiberinsertion region 131 a/131 b, a close-fitting region 132 a/132 b, and afiber end region 133 a/133 b. The fiber insertion region 131 a/131 b maybe frusto-conical in shape to aid in guiding the optical fiber 156 a/156b into the first and second fiber securing devices 122 a, 122 b. Theclose-fitting regions 132 a/132 b may have a diameter that issubstantially similar to that of an outside diameter of the opticalfibers 156 a/156/b such that the optical fibers are maintained withinthe close-fitting regions without substantial freedom of movement. Thefiber end region 133 a/133 b of the first and second fiber installationfeatures 130 a, 130 b is an opening at a signal surface 137 a/137 b ofthe first and second fiber securing devices 122 a, 122 b such that thefiber end regions 133 a, 133 b act as a first signal aperture and asecond signal aperture.

The first and second fiber securing devices 122 a, 122 b each comprisean engagement surface 134 a/134 b at an engagement end that tangentiallycontacts the first and second solder rings 126 a, 126 b when positionedwithin the first and second solder rings 126 a, 126 b, respectively. Theengagement surface 134 a/134 b may be configured as a chamfer, asillustrated in FIGS. 1C-1E, 1G, or other engagement shapes that aid inlocating the x-y-z position of the optical fiber 156 a, 156 b.

In an alternative embodiment, the optical component assembly 120 mayhave only a single fiber securing device rather than the two first andsecond fiber securing devices 122 a and 122 b. In this embodiment, thefirst and second fiber securing devices may be coupled together as asingle component having a first extension and a second extension. Forexample the first fiber installation feature 130 a may extend throughthe first extension, and the second fiber installation feature 130 b mayextend through the second extension, as described above with respect tothe first and second fiber securing devices 122 a, 122 b. However, inthis embodiment, the first and second fiber securing devices 122 a and122 b are connected together as a unitary component.

In one embodiment, an optical fiber (e.g., first optical fiber 156 a) isinserted into the first fiber installation feature 130 a or the secondfiber installation feature 130 b by pushing an end of the optical fiberinto the fiber insertion region 131 a, through the close-fitting region132 a and up against the fiber end region 133 a. The end of the opticalfiber should be referenced to the signal surface 137 a/137 b of thefiber securing device. In one embodiment, a temporary stop is placedagainst the signal surface 137 a/137 b such that the ends of the firstand second optical fibers 156 a, 156 b abut the temporary stop and donot extend past the signal surface 137 a/137 b of the first and secondfiber securing devices 122 a, 122 b (i.e., the ends of the first andsecond optical fibers 156 a, 156 b are located at the fiber end regions133 a, 133 b). The first and second optical fibers 156 a, 156 b may bebonded within the first and second fiber securing devices 122 a, 122 bby use of an adhesive. In another embodiment, the first and secondoptical fibers 156 a, 156 b, may be inserted through the fiberinstallation features 130 a/130 b of the first and second fiber securingdevices 122 a, 122 b such that the ends of the first and second opticalfibers 156 a, 156 b extend past the fiber end regions 133 a/133 b. Thefirst and second optical fibers 156 a, 156 b may then be cleaved (e.g.,by a laser) such that the ends of the first and second optical fibers156 a, 156 b are either flush with the fiber end regions 133 a/133 b, orare at a known, specified distance from the fiber end regions 133 a/133b The ends of the first and second optical fibers 156 a, 156 b should besubstantially referenced to the fiber end regions 133 a/133 b such thatthey are at a known z-axis distance d from the surface 123 of the activecomponent substrate 127 (i.e., a known predetermined height measuredfrom the fiber end region 133 a/133 b to the surface 123 of the activecomponent substrate 127). In one embodiment, the ends of the opticalfibers 156 a, 156 b are located substantially 50 μm from the fiber endregions 133 a/133 b.

Referring specifically now to FIG. 1E, the first optical fiber 156 a andthe first fiber securing device 122 a and the second optical fiber 156 band the second fiber securing device 122 b are coupled to the activecomponent assembly 121 such that the engagement surfaces 134 a/134 btangentially contact the first and second solder rings 126 a, 126 b,respectively. The first and second fiber securing device 122 a, 122 b,may be secured to the first and second solder rings 126 a, 126 b by anindex of refraction matching material that is substantially transparentto the optical radiation emitted and received by the light emittingcomponent 141 and the light receiving component 142, respectively suchthat the optical signals emitted by the light emitting component 141 mayenter the optical fiber and the optical signals propagating in theoptical fiber may be received by the light receiving component 142(e.g., an epoxy or other adhesive).

The first and second solder rings 126 a and 126 b act as alignmentcomponents that precisely align the first and second fiber securingdevices 122 a and 122 b to a predetermined spatial optical couplinglocation of the active component substrate 127 (e.g., a predeterminedlight emitting location with respect to the light emitting component 141and a predetermined light receiving location with respect to the lightreceiving component 142). As described above, the light emittingcomponent 141 and the light receiving component 142 are preciselyaligned with the first and second solder rings 126 a, 126 b,respectively, in the x- and y-axis directions by use of a single soldermask. Because of the known height of the first and second solder rings126 a, 126 b (i.e., by the known surface tension and amount of solderused to form the rings) as well as x and y position of the first andsecond solder rings 126 a and 126 b, the fiber end region 133 a/133 b ofthe first and second fiber securing devices 122 a, 122 b and thecorresponding ends of the first and second optical fibers 156 a, 156 bare substantially aligned in a specific spatial position relative to thetop surface of the light emitting component 141 and the light receivingcomponent 142, respectively, in x-, y-, and z-axis directions.

The signal surfaces 137 a/137 b of the first and second fiber securingdevices 122 a, 122 b are located at a known predetermined distance d(height) along the z-axis measured from the signal surfaces 137 a/137 bto the surface 123 of the active component substrate 127. Thepredetermined distance d is determined by the height and shape of thefirst and second solder rings 126 a, 126 b. The shape and location ofthe first and second solder rings 126 a, 126 b also positions the fiberend regions 133 a/133 b at a known x and y position with respect to theactive component substrate 127. In this manner, the fiber end region ofa fiber securing device may be substantially located at a predeterminedoptical coupling location with respect to an active optical component,such as a light emitting component or a light receiving component.Accordingly, the fiber securing devices and solder rings maysubstantially align an end of an optical fiber with an active componentfor optical signal transmission.

As illustrated in FIG. 1A, the optical component assembly 120 may becoupled to the mother printed circuit board 113 such that the activecomponents of the active component substrate are electrically coupled tothe components of the mother printed circuit board 113.

Referring now to FIGS. 2A-2E, another embodiment of an optical componentassembly 220 is illustrated. The optical component assembly 220generally comprises a fiber securing assembly configured as a singleoptically transparent fiber securing device 222, and an active componentassembly 221. Referring specifically to FIG. 2B, the active componentassembly 221 comprises an active component substrate 227 having a lightemitting component 141 and a light receiving component 142 coupledthereto at a light emitting component location and a light receivingcomponent location defined by pads 238 a and 238 b, respectively. Moreor fewer active optical components may be provided. Optical componentassemblies having both a light emitting component and a light receivingcomponent may be referred to as optical transceiver assemblies, and theactive component assembly 221 as a transceiver substrate assembly. Asdescribed above with respect to the embodiment illustrated in FIGS.1A-1G, the active component substrate 227 may be made from a dielectricmaterial, such as FR-4, for example.

The active component substrate 227 of the embodiment illustrated inFIGS. 2A-2E may comprise a first alignment location 237 a and a secondalignment location 237 b. As described in detail below, the first andsecond alignment locations 237 a and 237 b may assist in preciselyaligning the fiber securing device 222 and the active optical componentsto the active component substrate 227 by the use of a vision system (notshown). The first and second alignment locations 237 a and 237 b may beconfigured as reference marks that are printed on a surface 223 of theactive component substrate 227 at precise x- and y-axis coordinates,respectively. The light emitting component 141 and the light receivingcomponent 142 may be coupled to the surface 223 of the active componentsubstrate 227 by a vision die-attach system that uses the firstalignment location 237 a and the second alignment location 237 b asreference points. First and second pads 238 a and 238 b may belithographically defined at the same time as the first and secondalignment locations 237 a and 237 b. In one embodiment, the activecomponents may be directly aligned to their respective pads 238 a, 238b. The active component substrate 227 may further include electricalconnection vias to electrically couple the active component substrate227 and the active optical components to the mother printed circuitboard 113 (see FIG. 1A).

The fiber securing device 222 may comprise a first fiber installationfeature 230 a, a second fiber installation feature 230 b, a firstalignment aperture 226 a and a second alignment aperture 226 b. Thematerial chosen for the fiber securing device 222 should besubstantially transparent to the wavelength(s) of the optical radiationemitted and received by the light emitting component 141 and the lightreceiving component 142 such that the optical radiation may pass throughthe fiber securing device 222. Exemplary materials may include, by wayof example and not limitation, epoxy resins, polyurethanes,polycarbonates, and polyetherimides.

It is noted that the fiber securing device 222 illustrated in FIGS.2A-2E is configured to optically couple two optical fibers 156 a and 156b to two active optical components (e.g., the light emitting component141 and the light receiving component 142). However, it is should beunderstood that embodiments may be configured to optically couple moreor fewer optical fibers to more or fewer active components.

Referring specifically now to FIGS. 2C and 2E, the first and secondfiber installation features 230 a and 230 b are illustrated. FIG. 2Cillustrates the optical component assembly 220 showing the interiorfirst and second fiber installation features 230 a and 230 b, while FIG.2E provides a cross-sectional view of the optical component assembly220. Each of the first and second fiber installation features 230 a and230 b may comprise a fiber insertion region 231 a/231 b, a close-fittingregion 232 a/232 b, and a fiber end region 243 a/243 b within a bulk ofthe fiber securing device 222 material. The fiber insertion region 231a/231 b may comprise an opening at a fiber installation surface 228, andmay be frusto-conical in shape to ease insertion of the first and secondoptical fibers 156 a and 156 b into the first and second fiberinstallation features 230 a and 230 b.

The close-fitting region 232 a/232 b may be configured as a hole havingan end surface (i.e., a stop) that defines the fiber end region 243a/243 b. Therefore, the fiber end region 243 a/243 b of the embodimentsillustrated in FIGS. 2A-2E is located within a bulk region of the fibersecuring device 222. A diameter of the close-fitting region 232 a/232 bmay closely match the outer diameter of the first and second opticalfibers 156 a and 156 b.

Referring specifically to FIG. 2E, the end surface of the blind holedefining the fiber end region 243 a/243 b is located at a predetermineddistance d (height) along the z-axis measured from the fiber end region243 a/243 b to the surface 223 of the active component substrate 227.The predetermined distance d is determined by the depth of the blindhole of the close-fitting region 232 a/232 b. As described below, thepredetermined distance d sets the z-axis distance from of an end of thefiber optic cable to the active optical component. The location of thefirst and second fiber installation features 230 a and 230 b sets the x-and y-axis location of the fiber ends.

The first optical fiber 156 a may be inserted into the first fiberinstallation feature 230 a such that an end of the first optical fiber156 a abuts the fiber end region 243 a. The second optical fiber 156 bmay be inserted into the second fiber installation feature 230 b suchthat an end of the second optical fiber 156 b abuts the fiber end region243 b. The first and second optical fibers 156 a and 156 b may then besecured within the first and second fiber installation features 230 aand 230 b by an index-matching, transparent material (e.g., anindex-matching epoxy material). In one embodiment, a small vent hole(not shown) may extend from the fiber end region 243 a/243 b to anattachment surface 224 to expose the first and second fiber installationfeatures 230 a, 230 b to ambient at the bottom of the fiber securingdevice 222 such that excess air may escape upon insertion of the opticalfiber and the epoxy material.

Referring to both FIGS. 2C and 2E, the fiber securing device 222 mayfurther comprise an active optical component recess 244 in an attachmentsurface 224 such that the light emitting component 141 and the lightreceiving component 142 may be positioned within the active opticalcomponent recess 244 when the fiber securing device 222 is coupled tothe active component substrate 227. The active optical component recess244 may have a configuration other than the configuration depicted inFIGS. 2C and 2E. For example, the active optical component recess may beconfigured as two recesses, with one recess for the light emittingcomponent 141 and one recess for the light receiving component 142.

The first alignment aperture 226 a is located at a first end of thefiber securing device 222 and the second alignment aperture 226 b islocated at an opposite, second end of the fiber securing device 222. Thex- and y-axis coordinates of the first alignment aperture 226 a and thesecond alignment aperture 226 b may be held in tight tolerance of oneanother for precise alignment with the first and second alignmentlocation 237 a, 237 b of the active component substrate 227. Embodimentsare not limited to the particular location of the first and secondalignment apertures 226 a and 226 b. Further, more than two alignmentapertures may be utilized in other embodiments.

The fiber securing device 222 may be aligned with, and positioned on,the surface 223 of the active component substrate 227 by an automatedprocess that utilizes vision alignment. During vision-system assembly ofthe fiber securing device 222 to the surface 223 of the active componentsubstrate 227, the first and second alignment apertures 226 a and 226 bare positioned in the x- and y-axis directions to align with the firstand second alignment locations 237 a and 237 b, respectively. In thismanner, the first and second alignment apertures 226 a and 226 b and thefirst and second alignment locations 237 a and 237 b act as alignmentcomponents that align the fiber securing device 222 to the activecomponent substrate 227. Therefore, the fiber securing device 222, thelight emitting component 141, and the light receiving component 142 arecoupled to the surface 223 of the active component substrate 227 usingthe same first and second alignment locations 237 a, 237 b as referencepoints. An attachment surface of the fiber securing device 222 thatcontacts the surface 223 of the active component substrate 227 may besecured by an adhesive, such as epoxy.

The fiber securing device 222 aligns fiber ends of the first and secondoptical fibers 156 a and 156 b to predetermined optical couplinglocations in x-, y-, and z-axis directions relative to the respectiveactive optical component (e.g., the light emitting component 141 and thelight receiving component 142). A predetermined optical couplinglocation is the location that provides the greatest optical couplingbetween the end of the optical fiber and the active component. The fiberend should be aligned in both left and right directions, as well as inheight for optimum optical coupling.

As described above, the location of the end surface of the hole 232a/232 b (i.e., the fiber end region 243 a/243 b) establishes a knownz-axis position of the end of the optical fibers with respect to thesurface 223 of the active component substrate 227. The x- and y-axiscoordinates are established by the alignment of the first and secondalignment apertures 226 a and 226 b with the first and second alignmentlocations 237 a and 237 b. In this manner, the fiber end region(s) ofthe fiber securing device may be substantially located at apredetermined optical coupling location with respect to an activeoptical component, such as a light emitting component or a lightreceiving component. Accordingly, the fiber securing device and thealignment locations on the active component substrate may substantiallyalign an end of an optical fiber with an active component for opticalsignal transmission.

In some embodiments, the fiber securing device 222 may further compriseone or more notches to reduce and/or prevent optical cross-talk betweenthe emitted and received optical signals. The embodiment depicted inFIGS. 2A-2E comprises a first notch 236 on a top of the fiberinstallation surface 228. The first notch 236 is positioned between thefirst and second fiber installation features 230 a and 230 b to preventoptical cross talk between optical signals propagating in the first andsecond optical fibers 156 a and 156 b. The illustrated embodimentfurther comprises a second notch 239 a and the third notch 239 b on abottom or attachment surface 224 of the fiber securing device 222. Thesecond notch 239 a may extend from the active optical component recess244 and be positioned between the first fiber installation feature 230 aand the first notch 236. The third notch 239 b may extend from theactive optical component recess 244 and be positioned between the firstnotch 236 and the second fiber installation feature 230 b.

Referring now to FIGS. 3A-3G, another embodiment of an optical componentassembly 320 is illustrated. The optical component assembly 320generally comprises a two-component fiber securing assembly configuredas a fiber securing device 322 and a collar 360, and an active componentassembly 321. Referring specifically to FIG. 3B, the active componentassembly 321 comprises an active component substrate 327 having a lightemitting component 141 and a light receiving component 142 coupledthereto at a light emitting component location and a light receivingcomponent location, respectively. More or fewer active opticalcomponents may be provided. Optical component assemblies having both alight emitting component and a light receiving component may be referredto as optical transceiver assemblies, and the active component assembly321 a transceiver substrate assembly. The active component substrate 327may be made from a dielectric material, such as FR-4, for example.

A surface 323 of the active component substrate 327 may include a slot365 into which a light baffle 347 (described below) of the fibersecuring device 322 may be positioned during mechanical engagement ofthe fiber securing device 322 and the active component substrate 327.The active component substrate 327 may also include pin holes 368 a and368 b to enable mechanical engagement and alignment of the fibersecuring device 322 to the active component substrate 327. Additionally,electrically conductive vias 369 may extend through the thickness of theactive component substrate 327 that form a Faraday cage to electricallyisolate the active components of the active component assembly 321. Itis noted that electrically conductive vias 369 may be utilized in anyembodiment of the active component substrate 327 illustrated in theappended figures, and not only the two-component fiber securing assemblyembodiment illustrated in FIGS. 3A-3G.

In some embodiments, the active component substrate 327 may furthercomprise a mechanical key notch 367 such that the optical componentassembly 320 may be coupled to the mother printed circuit board 113 inonly one correct orientation. Conductive pads 366 a and 366 b may beprovided to couple the active component substrate 327 of the opticalcomponent assembly 320 to the mother printed circuit board 113 (see FIG.3F, which illustrates a bottom view of the active component substrate327).

As illustrated in FIGS. 3A-3G, the collar 360 is mechanically coupled tothe active component substrate 327 and aligns the fiber securing device322 to the proper location with respect to the active component assembly321 to thereby align the ends of the first and second optical fibers 156a and 156 b with the light emitting component 141 and the lightreceiving component 142, respectively. In one embodiment, the collar 360comprises an inner wall 362 that is non-continuous and is generally “C”shaped. The inner wall 362 may define a collar gap 364, which is theopened area of the “C” shape. The collar gap 364 exposes a region of anedge 370 of the active component substrate 327. In another embodiment,the inner wall 362 may be continuous such that no opened area is formed.

The inner wall 362 of the collar 360 may have a conical, oval shape thatis configured to mate with a corresponding conical, oval-shapedengagement surface 348 of the fiber securing device 322. Otherengagement surface configurations are also possible. As shown in FIG.3B, the collar 360 may comprise coupling pins 372 a and 372 b that arepositioned and configured to be inserted into the pin holes 368 a and368 b of the active component substrate 327. The collar 360 may bemechanically coupled to the active component substrate 327 by insertionof the coupling pins 372 a and 372 b into the pin holes 368 a and 368 b.The coupling pins 372 a and 372 b may be staked (e.g., by theapplication of heat or ultrasonic energy) to permanently attach thecollar 360 to the active component substrate 327.

Once attached to the active component substrate 327, the collar 360defines a collar opening 361 that exposes a region 363 of the surface323 of the active component substrate 327. As depicted in FIG. 3C, thelight emitting component 141 and the light receiving component 142 arepositioned on the region 363 of the active component substrate 327exposed by the collar opening 361. In one embodiment, the collar 360 iscoupled to the active component substrate 327 prior to populating theactive component substrate 327 with the active optical components, suchas the light emitting component 141 and the light receiving component142. In this embodiment, a vision die-attach system is used to populatethe active component substrate 327 that uses the exposed edge 370 of theactive component substrate 327 and the inner wall 362 as a referencesurfaces for the vision die-attach system. In embodiments that do nothave a collar gap 364, the collar opening 361 may expose two edges ofthe active component substrate 327 such that the exposed two edges maybe used as reference surfaces. In this manner, the light emittingcomponent 141 and the light receiving component 142 may be accuratelypositioned on the active component substrate 327 with respect to thecollar 360 independent from features or markings on the surface 323 ofthe active component substrate 327.

The fiber securing device 322, which is configured to mate with thecollar 360 at the collar opening 361, may comprise a first fiberinstallation feature 330 a, a second fiber installation feature 330 b, alight baffle 347, and tabs 345 and 346. One or more additional fiberinstallation features (or fewer) may be provided depending on the numberof active optical components in the assembly. The material chosen forthe fiber securing device 322 should be substantially opaque to thewavelength(s) of the optical signals emitted by and received by thelight emitting component 141 and the light receiving component 142.Exemplary materials may include, by way of example and not limitation,epoxy resins, polyurethanes, polycarbonates, and polyetherimides.

It is noted that the fiber securing device 322 illustrated in FIGS.3A-3G is configured to optically couple two optical fibers 156 a and 156b to two active components (e.g., the light emitting component 141 andthe light receiving component 142). However, it is should be understoodthat embodiments may be configured to optically couple more or feweroptical fibers to more or fewer active optical components.

The first and second fiber installation features 330 a and 330 b fullyextend through a bulk of the fiber securing device 322 from a fiberinstallation surface 338 to a signal surface 333 (see FIG. 3G).Referring specifically to FIGS. 3D and 3G, the first and second fiberinstallation features 330 a and 330 b may each comprise a fiberinsertion region 331 a/331 b, a frusto-conical region 371 a/371 b, aclose fitting region 332 a/332 b, and a fiber end region 375 a/375 b.The fiber insertion region 331 a/331 b may comprise an opening at thefiber insertion surface 368 that tapers to the close-fitting region 332a/332 b via the frusto-conical region 371 a/371 b. The diameter of thefiber insertion region 331 a/331 b may be greater than an outer diameterof the first and second optical fibers 156 a and 156 b for ease ofinsertion of the optical fibers into the first and second fiberinstallation feature 330 a and 330 b. A diameter of the close-fittingregion 332 a/332 b may closely match the outer diameter of the first andsecond optical fibers 156 a and 156 b. The fiber end regions 375 a and375 b open to the signal surface 333 to form a first signal aperture anda second signal aperture (see FIG. 3G).

The first and second optical fibers 156 a and 156 b should be insertedinto the first and second fiber installation features 330 a and 330 b,respectively, such that the ends of the first and second optical fibers156 a and 156 b are positioned at the fiber end region 375 a and 375 band are substantially referenced to the signal surface 333. As describedabove, the fiber ends may be flush with the signal surface 333 or extenda known distance from the signal surface 333 if laser cleaved. Asdescribed above with respect to the embodiments illustrated in FIGS.1A-1G, for a flush design a temporary stop may be positioned against thesignal surface 333 such that the ends of the first and second opticalfibers 156 a and 156 b abut the temporary stop and are positioned at thefiber end regions 375 a and 375 b of the first and second fiberinstallation features 330 a and 330 b. The first and second opticalfibers 156 a and 156 b may then be secured within the first and secondfiber installation features 330 a and 330 b with a transparent,index-matching adhesive material. In another embodiment, a temporarystop may not be utilized, but rather the optical fibers may be cleavedsuch that their ends are positioned within the fiber end regions 375a/375 b (e.g., by a laser).

In one embodiment, a light baffle 347 extending from the signal surface333 may be utilized to further minimize any optical cross talk betweenoptical signals propagating within the first and second optical fibers156 a and 156 b. The light baffle 347, which is substantially opaque tothe optical signals within the first and second optical fibers 156 a and156 b, may be positioned between the fiber end regions 375 a and 375 b.It should be understood that the light baffle 347 may be configured asother shapes, such as “V” shaped, rounded, or knife-edged.

The fiber securing device 322 is mechanically coupled to the collar 360,thereby aligning the ends of the first and second optical fibers 156 aand 156 b with respect to the light emitting component 141 and the lightreceiving component 142 because the light emitting component 141 and thelight receiving component 142 are positioned on the active componentsubstrate 127 with respect to the collar 360 via a vision system. Themale conical and oval shape of the engagement surface 348 of the fibersecuring device 322 is configured to engage the female conical and ovalshape of the inner wall 362. The light baffle 347 may be positioned intothe slot of the active component substrate 327 when the fiber securingdevice 322 is coupled to the collar 360. In one embodiment, the fibersecuring device 322 is coupled to the collar 360 and the activecomponent substrate 327 by an index-matching material. In an alternativeembodiment, the fiber securing device 322 is coupled to the collar 360by mechanical features, such as by snap-fit.

The illustrated, exemplary fiber securing device 322 further comprises afirst tab 345 and a second tab 346. The second tab 346 is sized andpositioned on a side of the fiber securing device 322 to close off thecollar gap 364 formed by the non-continuous inner wall 362. The secondtab 346 may also provide a mechanical keying feature that permitsassembly in only one orientation of the fiber securing device 322 to thecollar 360. The second tab 346 may ensure that the fiber securing device322 is coupled to the collar 360 such that the signal surface 333 is apredetermined distance d (height) measured from the surface 323 of theactive component substrate 327. The first tab 345 may also providemechanical keying functionality.

Referring now to FIG. 3D, the collar 360 acts as an alignment componentthat aligns the fiber end regions 375 a and 375 b to predeterminedactive optical locations with respect to the active optical components(i.e., the light emitting component 141 and the light receivingcomponent 142). The ends of the optical fibers 156 a and 156 b aretherefore aligned in x-, y-, and z-axis directions with respect to thelight emitting component 141 and the light receiving component 142. Thepredetermined height in the z-axis is established by the engagement ofthe fiber securing device 322 with the collar 360 such that the signalsurface 333 is the predetermined distance d from the surface 323 of theactive component substrate 327. The x- and y-axis coordinates of theends of the first and second optical fibers 156 a and 156 b are alsoestablished by the mechanical engagement of the fiber securing device322 with the collar 360, and that the light emitting component 141 andthe light receiving component 142 are coupled to the active componentsubstrate 327 using the inner wall 362 of the collar 360 as a reference.In this manner, the fiber end region(s) of the fiber securing device maybe substantially located at a predetermined optical coupling locationwith respect to an active optical component, such as a light emittingcomponent or a light receiving component. Accordingly, the fibersecuring device and the collar may substantially align an end of anoptical fiber with an active component for optical signal transmission.

Referring now to FIGS. 4A-4E, another embodiment of an optical componentassembly 420 is illustrated. The illustrated optical component assembly420 generally comprises an active component assembly 421 and a fibersecuring assembly configured as a holder device 422, a first fibersecuring device 480 a, and a second fiber securing device 480 b. In oneembodiment, the first and second fiber securing devices 480 a and 480 bare cylindrical ferrules. Referring specifically to FIG. 4B, the activecomponent assembly 421 comprises an active component substrate 427having a first active optical component (e.g., a light emittingcomponent 141) and a second active optical component (e.g., a lightreceiving component 142) coupled thereto at a predetermined firstlocation (e.g., a light emitting component) and a predetermined secondlocation (e.g., a light receiving component location) along the x-axisand the y-axis, respectively. More or fewer active optical componentsmay be provided. Optical component assemblies having both a lightemitting component and a light receiving component may be referred to asoptical transceiver assemblies, and the active component assembly 421 atransceiver substrate assembly. The active component substrate 427 maybe made from a dielectric material, such as FR-4, for example.

The exemplary active component substrate 427 has two pin holes 468 a and468 b to receive coupling pins 484 a and 484 b of the holder device 422as described in more detail below. More or fewer pin holes may beutilized to secure the holder device 422 to the active componentassembly 421.

The active component substrate 427 may further comprise castellationsand electrically conductive bond pads as described above to electricallycouple the optical component assembly 420 to the mother printed circuitboard 113 and/or prevent electrical cross-talk between the activeoptical components.

The holder device 422 may be configured as a rectangular plastic moldedcomponent that is substantially opaque to the wavelength of opticalradiation emitted and received by the light emitting component 141 andthe light receiving component 142. The holder device generally comprisesa first fiber-locating hole 482 a and a second fiber-locating hole 482 bthat extend from a first surface 424 to a second surface 438, twocoupling pins 484 a and 484 b, and an active optical component recess487 at the first surface 424.

The first fiber-locating hole 482 a and second fiber-locating hole 482 bare precision holes that are dimensioned to accept the first fibersecuring device 480 a and the second fiber securing device 480 b,respectively. Referring to FIGS. 4C and 4D, the first and secondfiber-locating holes 482 a, 482 b have an engagement feature 486 a, 486b proximate to the active optical component recess 487. The engagementfeature 486 a, 486 b, which may comprise a chamfered region in oneembodiment, may be configured to mate with an engagement surface of afiber securing device 480 a, 480 b, as described below. Otherarrangements may also be utilized. For example, the engagement featuremay be configured as a circumferential rim upon which a correspondingcircumferential rim or structure of the first and second fiber securingdevices may rest.

The active optical component recess 487 may be configured in a varietyof geometrical configurations and should be such that, when the holderdevice 422 is coupled to the active component substrate 427, the lightemitting component 141 and the light receiving component 142 aremaintained within the active optical component recess 487. Theillustrated optical component recess 487 further comprises a lightemitting component hole 487 a and a light receiving component hole 487 bof which the first and second fiber securing devices 480 a, 480 bcontact when inserted into the holder device 422 and are located in therespective stop positions (see FIGS. 4D and 4E). In an alternativeembodiment, at least a portion of the active optical component recess487 may extend to one or more sides of the holder device 422 to providean epoxy vent path through which excess index matching epoxy may flow.

The coupling pins 484 a and 484 b may extend from the first surface 424of the holder device 422. As shown in FIG. 4B, the coupling pins 484 aand 484 b are configured to be inserted into the pin holes 468 a and 468b of the active component substrate 427. In one embodiment, the couplingpins 484 a and 484 b have different diameters such that that holderdevice 422 may be coupled to the active component substrate 427 in onlyone orientation. The diameters of the coupling pins 484 a, 484 b may besmaller than the diameters of the corresponding pin holes 468 a, 468 bsuch that the coupling pins 484 a, 484 b loosely fit within the pinholes 468 a, 468 b to achieve rough alignment between the holder device422 and the active component substrate 427.

In one embodiment, the first and second fiber securing devices 480 a and480 b may be similar to the first and second fiber securing devices 122a and 122 b illustrated in FIGS. 1A-1G. More or fewer fiber securingdevices may be utilized depending on the number of active components inthe optical component assembly. The first and second fiber securingdevices 480 a and 480 b have an engagement surface 434 a, 434 b thatsubstantially matches the engagement features 486 a, 486 b of the holderdevice 422 such that the engagement surfaces 434 a, 434 b mate with theengagement features 486 a, 486 b when the fiber securing devices 480 aand 480 b are coupled to the holder device 422.

Referring to FIG. 4D, the first and second fiber securing devices 480 a,480 b are configured to receive and secure an optical fiber, such asfirst and second optical fibers 156 a and 156 b shown in FIG. 4A. Thefirst and second fiber securing devices 480 a, 480 b may be configuredas a ceramic ferrule having a fiber installation feature 430 a, 430 b,respectively, fully extending therethrough. The fiber installationfeatures 430 a, 430 b comprise a fiber insertion region 431 a/431 b, aclose-fitting region 432 a/432 b, and a fiber end region 433 a/433 b.The fiber insertion region 431 a/431 b may be frusto-conical in shape toaid in guiding the optical fiber 156 a/156 b into the first and secondfiber securing devices 480 a, 480 b. The close-fitting regions 432 a/432b may have a diameter that is substantially similar to that of anoutside diameter of the optical fibers 156 a/156/b such that the opticalfibers are maintained within the close-fitting regions withoutsubstantial freedom of movement. The fiber end region 433 a/433 b of thefirst and second fiber installation features 430 a, 430 b is an openingat a signal surface 437 a/437 b of the first and second fiber securingdevices 480 a, 480 b such that the fiber end regions 433 a, 433 b act asa first signal aperture and a second signal aperture.

In one embodiment, the first optical fiber 156 a is inserted into thefirst fiber securing device 480 a and the second optical fiber 156 b isinserted into the second securing device 480 b such that the firstsecond optical fibers extend beyond the first and second signalaperture, respectively. The first and second optical fibers 156 a, 156 bmay be cleaved off at a precise distance with respect to the signalsurface 437 a/437 b (or flush with the signal surface 437 a/437 b insome embodiments). The optical fibers may be secured within the fibersecuring devices with an adhesive.

In one embodiment, the light emitting component 141 and the lightreceiving component 142 may be first die-attached to the activecomponent substrate 427 using a vision die-attach system that usesreference features on the active component substrate 427 as fiducialreferences (e.g., metal traces in the shape of a circular ring). Theholder device 422 may be positioned onto the active component substrate427 with the vision die-attach system using the light emitting component141 and the light receiving component 142 as fiducial references toprecisely align the holder device 422 with respect to the light emittingcomponent 141 and the light receiving component 142. In this embodimenta “look down” vision alignment method is used such that the visionsystem looks down through the light emitting component hole 487 a and/orthe light receiving component hole 487 b to see the light emittingcomponent 141 and/or light receiving component 142 for accurateplacement of the holder device 422. Accordingly, this embodiment may notrequire a “look up/look down” vision alignment method in which onecamera looks up at the item to be positioned and a second camera looksdown at the placement surface, wherein an overlapping of the imagesindicates an alignment. However, some embodiments may utilize such as“look up/look down” approach.

The coupling pins 484 a and 484 b are then positioned within the pinholes 468 a and 468 b. In one embodiment, while the holder device 422 istemporarily held in place by the vision die-attach system, the holderdevice 422 is tacked in place using UV curing adhesive on the couplingpins 484 a and 484 b in the loose-fitting pin holes 468 a and 468 bfollowed by a structural adhesive later in the process.

The active optical component recess 487 may be filled with an indexmatching adhesive and the first and second fiber securing devices 480 a,480 b (having the first and second optical fibers 156 a and 156 bpositioned therein) positioned within the first and secondfiber-locating holes 482 a and 482 b. The engagement surface 434 a/434 bof the first and second fiber securing devices 480 a and 480 b (e.g., achamfer or a square shoulder) determines the depth that the first andsecond fiber securing devices 480 a and 480 b are inserted into thefirst and second fiber-locating holes 482 a and 482 b. As shown in FIG.4D, the engagement end of the first and second fiber securing devices480 a and 480 b abuts the light emitting component hole 487 a and thelight receiving component hole 487 b to establish the signal surface 437a/437 b of the first and second fiber securing device 480 a and 480 b ata predetermined distance d (height) measured from the surface 423 of theactive component substrate 427. In one embodiment, a vent hole (notshown) is provided in the holder device 422 to allow excess indexmatching adhesive to escape.

The holder device 422 acts as an alignment component that aligns thefiber end regions 433 a and 433 b with respect to predetermined activeoptical locations of the active optical components (i.e., the lightemitting component 141 and the light receiving component 142). The endsof the optical fibers 156 a and 156 b are aligned in x-, y-, and z-axisdirections with respect to the light emitting component 141 and thelight receiving component 142. The precisely-located fiber-locatingholes 482 a and 482 b and the placement of the holder device 422 withrespect to the light emitting component 141 and/or the light receivingcomponent 142 establish the x- and y-axis positions of the ends of thefirst and second optical fibers 156 a and 156 b. The predeterminedheight in the z-axis is established by the engagement of the first andsecond fiber securing devices 480 a and 480 b with the engagementfeatures 486 a and 486 b of the holder device 422 such that the signalsurface 437 a/437 b is the predetermined distance d from the surface 423of the active component substrate 427. In this manner, the fiber endregion(s) of the fiber securing device may be substantially located at apredetermined optical coupling location (e.g., predetermined first andsecond location) with respect to an active optical component, such as alight emitting component or a light receiving component. Accordingly,the fiber securing devices and the holder device may substantially alignan end of an optical fiber with an active component for optical signaltransmission.

It should now be understood that embodiments described herein mayprecisely couple an end of an optical fiber to an active opticalcomponent, such as a light emitting component or a light receivingcomponent, using relatively low cost components. Embodiments maycomprise an active component assembly comprising an active componentsubstrate having active optical components coupled thereto, and a fibersecuring assembly into which optical fibers may be inserted. Alignmentfeatures are provided to substantially align ends of the optical fibers(or fiber) with the active component(s).

It is noted that terms like “typically,” when utilized herein, are notintended to limit the scope of the claimed invention or to imply thatcertain features are critical, essential, or even important to thestructure or function of the claimed invention. Rather, these terms aremerely intended to highlight alternative or additional features that mayor may not be utilized in a particular embodiment of the presentinvention.

For the purposes of describing and defining the present invention it isnoted that the terms “approximately” and “about” are utilized herein torepresent the inherent degree of uncertainty that may be attributed toany quantitative comparison, value, measurement, or otherrepresentation.

What is claimed is:
 1. An optical transceiver assembly comprising: anactive component assembly comprising an active component substratecomprising at least two pin holes, a first active optical component, anda second active optical component, wherein the first active opticalcomponent and the second active optical component are coupled to theactive component substrate; a first fiber securing device comprising afirst fiber installation feature, the first fiber installation featurecomprising a first signal aperture, and an engagement surface at anengagement end of the first fiber securing device, the engagementsurface comprising a shoulder; a second fiber securing device comprisinga second fiber installation feature, the second fiber installationfeature comprising a second signal aperture, and an engagement surfaceat an engagement end of the second fiber securing device, the engagementsurface comprising a shoulder; a holder device coupled to the activecomponent assembly, the holder device comprising: an active opticalcomponent recess at a first surface of the holder device, wherein thefirst active optical component and the second active optical componentare positioned at the active optical component recess; a firstfiber-locating hole and a second fiber-locating hole extending from asecond surface to the active optical component recess, the firstfiber-locating hole and the second fiber-locating hole comprising anengagement feature at the active optical component recess, wherein thefirst fiber securing device is maintained within the firstfiber-locating hole and the second fiber securing device is maintainedwithin the second fiber-locating hole such that the engagement surfaceof the first and second fiber securing devices contact the engagementfeature of the first and second fiber-locating holes, respectively; andat least two coupling pins extending from the first surface of theholder device; wherein: a diameter of the at least two coupling pins issmaller than a diameter of the at least two pin holes; the at least twocoupling pins are positioned within the at least two pin holes; and theholder device is mechanically coupled to the active component substratesuch that the first signal aperture of the first fiber securing deviceand the second signal aperture of the second fiber securing device aresubstantially located at a predetermined distance d from a surface ofthe active component substrate, the first signal aperture of the firstfiber securing device is substantially located at a predetermined firstlocation with respect to the first active optical component along anx-axis and a y-axis, and the second signal aperture of the second fibersecuring device is substantially located at a predetermined secondlocation with respect to the second active optical component along thex-axis and the y-axis, and a predetermined height in the Z-axis isestablished by the engagement of the first and second fiber securingdevices with the engagement features of the holder device.
 2. Theoptical transceiver assembly of claim 1, wherein the holder device isplaced on the active component substrate by a vision system.
 3. Theoptical transceiver assembly of claim 1, wherein the engagement featureof the holder device comprises a chamfered region.
 4. The opticaltransceiver assembly of claim 1, wherein the engagement feature of theholder device comprises a rim.
 5. The optical transceiver assembly ofclaim 1, wherein the active optical component recess is filled with anindex-matching epoxy material.
 6. The optical transceiver assembly ofclaim 1, wherein the first and second fiber installation features eachfurther comprise a fiber insertion region and a fitting region.
 7. Theoptical transceiver assembly of claim 1, wherein the active componentsubstrate further comprises a plurality of electrically conductive viaslocated between the first active optical component and the second activeoptical component.
 8. The optical transceiver assembly of claim 1,wherein the fiber securing device is cylindrical.
 9. The opticaltransceiver assembly of claim 1, wherein: the first and second fiberinstallation features each comprise a fiber insertion region and afitting region; and a diameter of the fiber insertion region is largerthan a diameter of the fitting region.